Cutting Path Design to Minimize Workpiece Displacement at Cutting Point: Milling of Thin-Walled Parts
Yusuke Koike, Atsushi Matsubara, Shinji Nishiwaki,
Kazuhiro Izui, and Iwao Yamaji
Kyoto University, Yoshidahonmachi, Sakyo-ku, Kyoto-shi, Kyoto 606-8501, Japan
Vibrations of a tool or workpiece during cutting operations shorten tool life and causes unwanted surface roughness. In this report, we propose an algorithm for determining the sequence of material removal, tool orientation, and feed directions, an algorithm minimizes workpiece displacements by considering workpiece stiffness and cutting force. In this research, the cutting path consists of the material removal sequence, tool orientation and feed directions. The material removal sequence changes the workpiece compliancematrix at the cutting points, and the feed directions and tool orientation change the direction of the cutting force. In our algorithm, workpiece displacements are reduced by changing the material removal sequence and applying the cutting force in the direction of higher workpiece stiffness. A numerical example demonstrates how the algorithm obtains appropriate cutting paths to mill a cantilever form. In the numerical example, three optimized cutting paths are compared with an unoptimized cutting path, a path used by an expert and based on the expert’s personal experience, to machine a low-stiffness workpiece. The obtained material removal sequence of the minimax compliance path is almost the same as that of the unoptimized cutting path. Workpiece displacements at the cutting point of three optimized cutting paths are approximately 10% smaller than those of the unoptimized cutting path. The minimum displacement path is the best of these three optimized cutting paths because fluctuations in workpiece displacements at cutting point are the smallest. These optimized cutting paths show the cutting path strategy as a rough cutting path for machining the thin-walled cantilever.
Kazuhiro Izui, and Iwao Yamaji, “Cutting Path Design to Minimize Workpiece Displacement at Cutting Point: Milling of Thin-Walled Parts,” Int. J. Automation Technol., Vol.6, No.5, pp. 638-647, 2012.
-  Y. Altintas, “Analytical Prediction of Three Dimensional Chatter Stability in Milling,” Japan Society of Mechanical Engineering Int. J., Series C, Vol.44, No.3, pp. 717-723, 2001.
-  E. Budak and A. Tekeli, “Maximizing Chatter Free Material Removal Rate in Milling through Optimal Selection of Axial and Radial Depth of Cut Pairs,” CIRP Annals – Manufacturing Technology, Vol.54, No.1, pp. 353-356, 2005.
-  V. Thevenot, L. Arnaud, G. Dessein, and G. C. Larroche, “Influence of material removal on the dynamic behavior of thin-walled structures in peripheral milling,” Machining Science and Technology, Vol.10, pp. 275-287, 2006.
-  T. Aijun and L. Zhanqiang, “Deformations of thin-walled plate due to static end milling force,” J. of Materials Processing Technology, Vol.206, pp. 345-351, 2008.
-  J. S. Tsai and C. L. Liao, “Finite-element modeling of static surface errors in the peripheral milling of thin-walled workpieces,” J. of Materials Processing Technology, Vol.94, pp. 235-246, 1999.
-  R. Sagherian and M. A. Elbestawi, “A Simulation System for Improving Machining Accuracy in Milling,” Elsevier Computer in Industry, Vol.14, pp. 293-305, 1990.
-  S. Ratchev, E. Govender, S. Nikov, K. Phuah, and G. Tsiklos, “Force and deflection modelling in milling of low-rigidity complex parts,” J. of Materials Processing Technology, Vol.143-144, pp. 796-801, 2003.
-  S. Ratchev, W. Huang, S. Liu, and A. A. Becker, “Modelling and simulation environment for machining of low-rigidity components,” J. of Materials Processing Technology, Vol.153-154, pp. 67-73, 2004.
-  S. Ratchev, S. Liu, W. Huang, and A. A. Becker, “Milling error prediction and compensation in machining of low-rigidity parts,” Int. J. of Machine Tools & Manufacture, Vol.44, pp. 1629-1641, 2004.
-  S. Ratchev, S. Liu, and A. A. Becker, “An advanced FEA based force induced error compensation strategy in milling,” Int. J. of Machine Tools & Manufacture, Vol.46, pp. 542-551, 2006.
-  J. K. Rai and P. Xirouchankis, “Finite element method based machining simulation environment for analyzing part errors induced during milling of thin-walled components,” Int. J. of Machine Tools & Manufacture, Vol.48, pp. 629-643, 2008.
-  M. Wan, W. H. Zhang, G. H. Qin, and Z. P. Wang, “Strategies for error prediction and error control in peripheral milling of thinwalled workpiece,” Int. J. ofMachine Tools &Manufacture, Vol.48, pp. 1366-1374, 2008.
-  H. S. Lee, A. Toride, T. Yamada, and S. Araki, “Study on the generation of micro shafts by turning operation,” J. of the Japan Society for Abrasive Technology, Vol.51, No.11, pp. 657-661, 2007. (in Japanese)
-  S. Smith and D. Dvorak, “Tool path strategies for high speed milling aluminum workpieces with thin webs,” Mechatronics, Vol.8, pp. 291-300, 1998.
-  L. N. López de Lacalle, A. Lamikiz, J. A. Sanchez, and M. A. Salgado, “Toolpath selection based on the minimum deflection cutting forces in the programming of complex surfaces milling,” Int. J. of Machine Tools & Manufacture, Vol.47, pp. 388-400, 2007.
-  C. M. Lee, S. W. Kim, K. H. Choi, and D. W. Lee, “Evaluation of cutter orientations in high-speed ball end milling of cantilevershaped thin plate,” J. of Materials Processing Technology, Vol.140, pp. 231-236, 2003.
-  C.M. Lee, S.W. Kim, Y. H. Lee, and D.W. Lee, “The optimal cutter orientation in ball end milling of cantilever-shaped thin plate,” J. of Materials Processing Technology, Vol.153-154, pp. 900-906, 2004.
-  S. Ratchev, S. Nikov, and I. Moualek, “Material removal simulation of peripheral milling of thin wall low-rigidity structures using FEA,” Advances in Engineering Software, Vol.35, pp. 481-491, 2004.
-  A. Vince, “A framework for the greedy algorithm,” Discrete Applied Mathematics, Vol.121, pp. 247-260, 2002.
-  P. Kattan, “MATLAB Guide to Finite Elements AN INTERACTIVE APPROACH,” Springer, pp. 367-396, 2008.
-  Y.W. Kwon and H. Bang, “The Finite ElementMethod UsingMATLAB Second Edition,” CRC Press, p. 351, 2000.
This article is published under a Creative Commons Attribution-NoDerivatives 4.0 International License.